Pillow with multi-layer sleep surfaces and multi-chamber inner body core

ABSTRACT

A pillow comprised of an outer shell  10  having an upper  3  and a lower  4  surface, each surface including a sleep surface  1 ; and an inner body core  20  having three chambers  9, 11, 12  made of four fabric layers  13, 14 ; wherein the inner body core  20  is enclosed inside the outer shell  10  to provide a pillow that is comfortable and healthy.

FIELD OF THE INVENTION

The present invention relates to a bed pillow for sleeping purposes. More particularly, the invention is a pillow having an outer shell with multi-layer sleep surfaces for moisture management, airflow enhancement and air/liquid barrier enclosing an independent multi-chamber inner body core. The outer shell is removable and washable to ensure a clean and healthy pillow. The inner body core is designed to be soft and supportive and to filter out indoor allergy-causing particles.

BACKGROUND OF THE INVENTION

Traditional bed pillows rely on simple designs and construction and are made with a limited number of fabrics and materials. As a result, traditional bed pillows present a number of disadvantages.

For example, the use of a single fill material results in an inconsistent comfort level. A pillow may be very comfortable at the beginning but it will rapidly flatten out depriving the user of the required support. Conversely, a pillow may provide consistent support but will do it at the expense of a soft and comfortable sensation.

In addition, the use of a single or few fabrics in the construction of the outer shell of a pillow limits the functionality of that shell in terms of comfort and health benefits to the user.

Further, traditional bed pillows become inherently unhealthy with use as they cannot prevent moisture, allergens, micro-organisms or dust from entering in and settling inside the pillow. Traditional bed pillows can also be difficult to thoroughly clean by washing and drying.

The invention is designed to overcome these disadvantages through the use of its structural design, material combinations and functional fabrics. Specifically, the invention pillow is constructed of a multi-chamber inner body core enclosed inside an outer shell. The inner body core is comprised of three chambers layered on top of one another and made of a fabric shell on the outside that acts as an indoor allergy-causing particle barrier. The three chambers can be filled with fluffy synthetic fibers, natural down or other soft material, latex flakes or solid sheets of latex rubber or other elastic material. Preferably, the two outer chambers of the inner body core are filled with the same material such as synthetic fiber, natural down or other soft material and the inner chamber is filled with flakes, solid sheets of latex rubber, foam or other elastic material. The inner body core is designed to provide durable comfort through the softness of the materials in the outer chambers and through the support of the material in the inner chamber.

The inner body core fits inside the outer shell. The outer shell is made of two multi-layer sleep surfaces on either side of the resulting pillow, which can be augmented by decorative fabrics. The sleep surfaces are made of three layers—a bottom air/liquid barrier fabric layer, a middle airflow enhancement layer (which is also inherently an insulation layer) and a top moisture management fabric layer. An optional fourth layer can be included, over and/or below the airflow enhancement layer and acts as a smoothing layer. The need for a smoothing fabric layer is based on the weight and design of the top moisture management fabric layer. Some weight and designs make the inclusion of the smoothing fabric necessary while other do not require it. The air/liquid barrier fabric and airflow enhancement layers may be bonded or quilted together or the bottom three layers may be bonded or quilted together if a smoothing fabric is used. These sleep surfaces cover about 60-100% of the upper/lower outer shell area depending on the pillow design and type of fabric used. A zipper and at least two pillow side vents are also included.

The particular construction of the sleep surfaces of the invention pillow enhances comfort and sleeping by promoting moisture management, airflow circulation, softness and reduced direct air and moisture transfers between the pillow and user. Moisture is reduced faster by the moisture management fabric layer than with conventional fabrics. That material absorbs and spreads moisture out across the fabric surface to enhance evaporative drying rates. That top fabric layer is also stretchable and soft to the touch and may include various patterns and design characteristics. The airflow enhancement layer promotes air circulation within its structure, reducing temperature exchanges between the user and the pillow and providing another element of softness. Limiting heat transfer between the user and the pillow reduces overheating. The bottom layer of air/liquid barrier fabric ensures that minimum amounts of air or moisture travel directly between the user and the inner body core of the pillow. This protects both the user and the pillow.

The invention delivers a refined level of comfort throughout the night. Due to the many comfort elements integrated in the design, the pillow feels very soft while being consistently supportive.

Pillows currently on the market do not provide all the structural features delivering the comfort, health and well-being characteristics provided by the invention.

The following patents and publications are representative of the prior art relevant to the invention. U.S. Pat. No. 4,508,044 to Downey discloses a pillow inserted into an “envelope” and sewn shut. The “envelope” is made of a cushioning material or foam. U.S. Pat. No. 7,152,263 to Delfs discloses a multi-chambered pillow. There are three chambers—an upper, lower and middle. The upper and lower chambers are filled with manmade or natural fibers and substantially no filing in the middle. U.S. Pat. No. 7,562,405 to Brogan discloses a pillow with interior chambers and inner and outer shell layers. U.S. Patent Publication No 2006/0075562 to DiGiroiamo discloses a pillow within an outer pillow shell. Baffles are used to create different size chambers within the pillow. U.S. Patent Publication No. 2014/0283303 to Rochlin discloses a washable pillow with multiple cases and a removable core. The inner shell includes foam pieces.

The current prior art does not disclose the unique structure of the invention pillow which includes a combination of a three chamber inner body core having a middle chamber filled with flakes or solid sheets of latex rubber or other elastic material surrounded by chambers filled with down or manmade fiber or other soft material; combined with an outer shell including sleep surfaces made of an air/liquid barrier fabric layer, an airflow enhancement layer, an optional smoothing fabric and a moisture management fabric layer is not taught or disclosed by the prior art.

SUMMARY OF THE INVENTION

In the present invention, these purposes, as well as others which will be apparent, are achieved generally by providing a pillow made of an outer shell having an upper and a lower surface, at least one surface including a multi-layered sleep surface; and an inner body core comprising three chambers. The inner body core is enclosed inside the outer shell to provide a pillow that is soft, comfortable, supportive, pure and healthy and helps to reduce moisture and temperature issues and promote airflow.

The sleep surface is preferably on both the upper and lower surfaces of the outer shell and also preferably covers between 60 to 100% of the upper and lower surfaces of the outer shell.

The sleep surface is preferably three layers made from bottom to top, of a air/liquid barrier fabric layer, a middle airflow enhancement layer and a moisture management fabric layer. In another embodiment, a fourth, smoothing fabric layer may be either on top and/or below the airflow enhancement layer.

Like any conventional pillow, a pillow case is not necessary but preferable to match the owner's bedding choices.

The air/liquid barrier fabric layer ensures that reduced levels of air and moisture travel directly between the user and the inner body core of the pillow.

The airflow enhancement layer limits heat transfer between the user and the pillow by promoting airflow within its structure thereby reducing overheating.

The outer shell further includes a closing device, which is preferably a zipper, Velcro® strips, buttons, snaps or other closure means. The closure means are also preferably invisible or decorative.

The outer shell further includes side vents to provide breathability to the pillow.

The inner body core chambers are filled with materials selected from the group consisting of synthetic fibers, natural down or other soft material, latex flakes, solid rubber or other elastic material.

The three chambers are an upper chamber, a middle chamber and a lower chamber. In preferred embodiments, the upper chamber and lower chamber are filled with the same material such as synthetic fibers, natural down or other soft material. The middle chamber is filled with latex rubber such as flakes or solid sheets, foam or other elastic materials.

The inner body core is made on the outside layer of a fabric material that is an indoor allergy-causing particle barrier. Commercially available fabric materials may be used in the invention and include materials such as Pristine. The invention however, is not limited to any particular fabric as long as the fabric provides the indoor allergy-causing particle barrier.

Other objects, features and advantages of the present invention will be apparent when the detailed description of the preferred embodiments of the invention are considered with reference to the drawings, which should be construed in an illustrative and not limiting sense.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of the outer shell of the invention pillow showing the sleep surfaces;

FIG. 2 illustrates the multi-layer sleep surface;

FIGS. 3A, 3B and 3C illustrate top/bottom, side and front/back views, respectively, of the outer shell of the invention pillow;

FIG. 4 is a schematic illustration of the inner body core elements of the invention pillow from a front/back cross-section view;

FIGS. 5A, 5B and 5C illustrate top/bottom, front/back and side views, respectively, of the inner body core; and

FIG. 6 illustrates the pillow of the invention (note the inner body core is not visible).

DETAILED DESCRIPTION OF THE INVENTION

As used throughout the specification, unless otherwise indicated, the following is a legend of the terms and structures according to the invention.

-   -   1—Sleep surfaces;     -   2—Side vent;     -   3—Outer shell upper surface;     -   4—Outer shell lower surface;     -   5—Sleep surface (top layer) Moisture management fabric layer;     -   6—Sleep surface (middle layer) Insulation/airflow enhancement         fabric layer;     -   7—Sleep surface (bottom layer) Air/liquid barrier fabric layer;     -   8—Sleep surface (optional layer) Smoothing fabric layer;     -   9—Upper chamber of the inner body core;     -   10—Outer Shell;     -   11—Lower chamber of inner the body core;     -   12—Central chamber of the inner body core;     -   13—Inner body core fabric layers—top and bottom layers;     -   14—Inner body core fabric layers—middle layers;     -   15—Closing device;     -   16—Border fabric material (optional);     -   17—Side fabric material (optional);     -   18—Inner body core section where there is a double layer of the         middle fabric layers;     -   20—Inner body core.

In general, in accordance with the invention, a pillow made of an outer shell including at least one multi-layered sleep surface and an inner body core comprising three chambers is provided.

As illustrated in FIG. 1, which shows the outer shell 10 viewed from the front perspective of the pillow, the outer shell 10 has an upper surface 3 and a lower surface 4. In preferred embodiments both the upper surface 3 and lower surface 4 includes a multi-layered sleep surface 1.

FIG. 6 illustrates the pillow of the invention showing the outer shell 10 which is the outside of the pillow. The sleep surfaces 1 on either side of the pillow can be augmented by a border or decorative fabrics 16. There is a closing device 15 along one length of the outer shell 10 to enable the insertion and removal of the inner body core 20. Closing devices used in the invention include, but are not limited to, zippers, Velcro® strips, buttons, snaps or other closure means. Placement of the closing device 15 on the outer shell 10 may also vary but in all instances provides for opening and closing to enable the removal of the independent inner body core 20.

As illustrated in FIG. 2, the sleep surfaces are comprised of a layer of an airflow enhancement fabric 6 sandwiched between a bottom layer of air/liquid barrier fabric 7 and a top layer of moisture management fabric 5. The airflow enhancement fabric is inherently an insulation layer.

Optionally, an additional layer of smoothing fabric 8 can be added between the airflow enhancement fabric 6 and the top layer 5 as required by the characteristics of the middle and top fabric layers. Alternatively, the smoothing fabric layer 8 can also be added in between airflow enhancement fabric 6 and the air/liquid barrier fabric 7.

The top layer of moisture management fabric 5 is a fabric made of synthetic or natural fibers or a combination with stretching and moisture-wicking characteristics. The airflow enhancement fabric 6 is a fabric or material made of synthetic or natural fibers or a combination with a three-dimensional structure through which air can flow. The air/liquid barrier fabric 7 is a fabric made of synthetic or natural fibers or a combination with the characteristic that the flow of air and moisture through the material is limited, reduced or eliminated.

Preferred materials used in the multi-layered sleep surface 1 include a polyester/lycra blend fabric for the moisture management layer 5; a 100% polyester fabric for the air flow enhancement layer 6; and a polyester fabric with a polyurethane film for the air liquid barrier fabric 7. The invention is not limited to these materials and it is within the scope of the invention that other materials having the physical characteristics described for each layer may be used instead.

The function of the sleep surface is to enhance the comfort of the user and optimize the healthy characteristics of the invention pillow. Comfort is enhanced in several ways. The optimal sleeping environment is created when the user experiences a soft luxurious feel, when airflow is promoted, when moisture is rapidly eliminated and when temperature exchange between the user and the pillow is reduced.

The sleep surfaces 1 provide a luxurious, soft, stretch feel of the top layer fabric 5 and cushioning of the airflow enhancement layer 6. They also enhance airflow. The moisture management top layer fabric 5 is breathable and the airflow management layer 6 promotes air circulation within its structure. The sleep surfaces 1 also provide moisture management. The moisture management top layer fabric 5 absorbs and spreads moisture out across the fabric surface to enhance the evaporative drying rate.

The sleep surfaces 1 also provide temperature control. The airflow enhancement layer 6 limits heat transfer between the user and the pillow, reducing overheating.

The sleep surfaces 1 also provide health benefits. The bottom layer of air/liquid barrier fabric 7 ensures that minimal levels of air and moisture travel directly between the user and the inside of the pillow. This protects both the user and the pillow. The outer shell 10 is also easily removable so it can be washed and dried, ensuring it is clean and healthy.

FIG. 3A illustrates the outer shell 10 viewed from the top (or bottom since both views are the same) perspective. As shown the sleep surfaces 1 preferably cover about 60-100% of the upper and lower surfaces 3, 4 of the outer pillow shell 10. FIG. 3B illustrates the outer shell 10 viewed from the front (or back since both views are the same) perspective. The sleep surfaces 1 are shown as well as the side vent 2. FIG. 3C illustrates the outer shell 10 viewed from the side. The sleep surfaces 1 and the side vent 2 are shown.

As illustrated in FIG. 4 the inner body core 20 of the invention is shown from a front (or back since both views are the same) perspective. The inner body core 20 is fully enclosed within the outer shell 10 to provide a pillow that is comfortable and healthy. The inner body core 20 has three chambers 9, 11, 12 and is made of a total of four fabric layers, top and bottom fabric layers 13 and two middle fabric layers 14.

Preferably the top and bottom fabric layers 13 of the inner body core 20 are made of a particle barrier fabric. The particle-barrier fabric which helps filter and reduce indoor allergy causing particles, may be used in the entire construction of the inner body core or just the outside layers only. In the latter case, the two middle layers will be made of a different type of fabric, preferably cotton.

The combination of the four layers of fabric of the inner body core creates three chambers—an upper chamber 9, a lower chamber 11 and a middle chamber 12. The three chambers can be the same size or different sizes. In a preferred embodiment, the upper 9 and lower 11 chambers are the same, while the middle chamber 12 is smaller and centered within the upper and lower chambers. In this embodiment as shown in FIG. 4 the two middle fabric layers 14 are sewn together to form a double layer 18 to separate the upper and lower chambers 9, 11. This leaves the middle chamber 12 centered within the inner body core 20 and stabilizes the middle chamber 12. In the embodiment where the middle chamber is the entire width of the inner core there is no need for the double layer 18.

Various types of fill can be used in each of the three chambers. The middle chamber 12 can be filled with either rubber, loose latex flakes, a solid latex core, foam or other elastic material. The upper 9 and lower 11 chambers can be filled with either natural down, synthetic fiber or other soft material. These upper 9 and lower 11 chambers are preferably filled with the same material. It is also within the scope of the invention that each chamber can each be filled with different materials, depending on the desired pillow.

The function of the inner body core is to provide comfort through softness and consistent support to the user and ensure the pillow remains a healthy environment. FIG. 5 illustrates views of the inner body core 20. FIG. 5A illustrates the inner body core viewed from the top (or bottom) perspective. FIG. 5B illustrates the inner body core viewed from the front (or back) perspective. FIG. 5C illustrates a cross-sectional view of the inner body core. This view shows the preferred embodiment, where the middle chamber 12 is smaller than the upper 9 and lower 11 chambers and is centered in the inner body core 20.

The elastic material in the middle chamber 12 provides consistent support as it will not flatten completely. The down/fiber or soft material in the outer chambers 9, 11 provides a soft and fluffy sinking-in sensation to the user. The combination ensures comfort as the pillow feels soft and airy while providing support through the night. Better comfort results in better sleep.

The particle barrier fabric used to make the outer layer 13 of the inner body core is designed to keep indoor allergy causing micro-organisms and dust particles typically found in homes from entering the pillow. The fabric can also be treated with a durable anti-microbial agent.

The outer shell 10 and the inner body core 20 in combination provide a pillow that is soft, supportive, pure and helps to reduce moisture and temperature issues and promote airflow. The term pure herein means that the air/moisture barrier in the sleep surface 1 and the filter fabric of the inner body core 20 prevent air particles and moisture from entering the core of the pillow thus keeping its contents pure as in their original condition.

The independent inner body core 20 is easily removed from the outer shell 10 so that the outer shell 10 can be washed as needed.

The invention pillow can be made in a variety of designs, sizes, colors and decorative fabric types as long as the core components and structure principles are present. For illustrative purposes only, in a standard size pillow the outer shell 10 is approximately 16 inches by 22 inches, the total height of the pillow is approximately 8 inches and the height of the side vents 2 approximately 2 inches. The inner body core 20 has essentially the same dimensions as the outer shell, however, in the preferred embodiment the middle chamber 12 is approximately 16 inches×11 inches×1 inch centered within the upper 9 and lower 11 chambers. The preferred fill in the middle chamber is a solid latex slab; surrounded by natural down or synthetic down in the upper 9 and lower 11 chambers. King and queen pillows, as well as pillows of other sizes and dimensions are within the scope of the invention.

FIG. 6 shows the pillow according to an embodiment of the invention. In this embodiment a border 16 surrounds the sleep surface 1. Side vents 2 and a side fabric material 17 are shown. The invention encompasses many variations including side vents 2 either on the left/right side of the pillow as illustrated in FIG. 6 or alternatively on the front/back side of the pillow (not illustrated). The side vents 2 are either the entire length of the side or some incremental portion thereof. Alternatively, the side fabric material 17 can be omitted and the top and bottom sleep surfaces 1 can be attached directly to each other.

The foregoing description of various and preferred embodiments of the present invention has been provided for purposes of illustration only, and it is understood that numerous modifications, variations and alterations may be made without departing from the scope and spirit of the invention as set forth in the following claims. 

What is claimed is:
 1. A pillow comprised of: an outer shell 10 having an upper surface 3 and a lower surface 4; at least one multi-layered sleep surface 1 on either said upper surface 3 or said lower surface 4; and an inner body core 20 having three chambers 9, 11, 12 made of four fabric layers 13, 14; wherein said inner body core 20 is enclosed inside said outer shell 10 to provide a pillow that is comfortable and healthy.
 2. The pillow according to claim 1, wherein said multi-layered sleep surface 1 is on both said upper surface 3 and said lower surface
 4. 3. The pillow according to claim 2, wherein said multi-layered sleep surface 1 covers between 60 to 100% of said upper surface 3 and said lower surface
 4. 4. The pillow according to claim 1, wherein said sleep surface 1 is at least three layers comprising an air/liquid barrier fabric layer 7, an airflow enhancement layer 6 and a moisture management fabric layer
 5. 5. The pillow according to claim 4, wherein said moisture management fabric layer 5 is the top closest to the user.
 6. The pillow according to claim 4, wherein said air/liquid barrier fabric layer 7 is the bottom layer and ensures that reduced levels of air and moisture travel between the user and said inner body core of the pillow.
 7. The pillow according to claim 4, wherein said airflow enhancement layer 6 is the middle layer and limits heat transfer between the user and the pillow reducing overheating.
 8. The pillow according to claim 4, wherein said sleep surface 1 may include a fourth smoothing layer 8 either above and/or below the middle airflow enhancement layer
 6. 9. The pillow according to claim 1, wherein said outer shell 10 further comprises a closing device 15 for easy removal and washing of the outer shell.
 10. The pillow according to claim 1, wherein said outer shell 10 further comprises side vents 2 to further facilitate airflow.
 11. The pillow according to claim 1, wherein said inner body core chambers 9, 11, 12 are filled with materials having an elastic consistency.
 12. The pillow according to claim 11, wherein said materials are selected from the group consisting of synthetic fibers, natural down or other soft material, latex, rubber, foam or other elastic material.
 13. The pillow according to claim 1, wherein said three chambers are an upper chamber 9, a middle chamber 12 and a lower chamber
 11. 14. The pillow according to claim 13, wherein said upper chamber 9 and lower chamber 11 are the same size and said middle chamber 12 is smaller and centered within said upper 9 and lower 11 chambers.
 15. The pillow according to claim 13, wherein said upper chamber 9 and said lower chamber 11 are filled with the same material.
 16. The pillow according to claim 13, wherein said upper chamber 9 and said lower chamber 11 are filled with synthetic fibers or natural down or other soft material.
 17. The pillow according to claim 13, wherein said middle chamber 12 is filled with latex, rubber, foam or other elastic material.
 18. The pillow according to claim 1, wherein said inner body core top and bottom fabric layers 13 comprises an outer material that is a particle barrier fabric.
 19. The pillow according to claim 1, wherein said outer shell 10 and said inner body core 20 in combination are soft, supportive, pure and helps to reduce moisture and temperature issues and promote airflow.
 20. The pillow according to claim 1, wherein said outer shell 10 is washable. 